Automated mat system and associated method

ABSTRACT

An automated mat system, including: a well structure; and a floor structure selectively disposed above the well structure, wherein the floor structure includes at least one oscillating region, at least one stationary region, and at least one vent region; wherein the at least one oscillating region is configured to clean dirt and debris from an object disposed on top of the floor structure opposite the well structure; and wherein the at least one vent region is configured to allow the dirt and debris to pass through the floor structure and into the well structure. The at least one oscillating region includes at least one brush tread strip, the at least one stationary region includes at least one carpet strip, and the at least one vent region includes at least one vent strip.

FIELD OF THE INVENTION

The present invention relates generally to an automated mat system and associated method. More specifically, the present invention relates to an automated mat system that may be used in a facility entrance or the like and that is operable for automatically cleaning an entrant's shoes or the like such that dirt and debris are not tracked or otherwise transported into the facility.

BACKGROUND OF THE INVENTION

In commercial and industrial facilities, for example, where high-volume foot traffic is common, dirt and debris from entrants' shoes can be a significant problem, requiring the ongoing attention of cleaning and maintenance personnel at considerable effort and expense. Thus, various conventional shoe cleaning mat systems have been developed.

One conventional shoe cleaning mat system is disclosed in US 2004/0261209 (McKay). McKay discloses a cleaning mat designed for placement on the floor and for cleaning the undersides of shoes, feet, and other objects. The mat includes a base layer formed of a non-slip polymer material and a non-woven absorbent cleaning layer generally co-extensive with the base layer and attached thereto. The cleaning layer has an upper surface for cleaning and a lower surface joined to the base layer. The cleaning layer has a plurality of openings defined there through.

Another conventional shoe cleaning mat system is disclosed in US 2010/0060118 (Tafil). Tafil discloses a self-cleaning entry mat. An illustrative embodiment of the self-cleaning entry mat includes a mat housing, a grate opening provided in the mat housing, a grate seated in the grate opening, and at least one collecting drawer extendable from the mat housing and positional between closed and opened positions. The collecting drawer is positioned beneath the grate opening when in the closed position.

A further conventional shoe cleaning mat system is disclosed in U.S. Pat. No. 5,881,427 (Offner). Offner discloses a floor mat or grate overlain by a web or paper fabric that is provided with a clamping device having at least one bar engaging the fabric for preventing shifting of the fabric on the grate or mat. The fabric can be removed, e.g. for cleaning or replacement, by releasing the clamping unit.

A still further conventional shoe cleaning mat system is disclosed in U.S. Pat. No. 6,067,688 (West). West discloses a shoe bottom or side cleaning device which is either portable or installed in a floor of an entrance to a dwelling or building, and is either manually or automatically operated. The device includes a plurality of side-by-side, elongated and rotated brushes, a funnel beneath the brushes, a motor for driving the brushes and a squirrel cage fan for collecting dirt from the brushes via the funnel, and a chamber for accumulating the collected dirt. The chamber can be equipped with a dirt collection bag. A central building vacuum system can assist the device's fan. The elongated brushes can have either a solid core or a “twisted” wire core.

A still further conventional shoe cleaning mat system is disclosed in U.S. Pat. No. 8,533,888 (Kessler). Kessler discloses a shoe cleaning doormat device for cleaning and disinfecting the soles of shoes and feet prior to a user's entry into a dwelling or building. The device is a doormat having a cleaning assembly having a disinfecting cleaning material surface and drying portions. Both portions are housed within a mat frame and exposed to a user through cutouts in the mat's upper surface. A disposable roll of moist, disinfecting wipe material provides the cleaning and disinfecting surface. An advancing button is operatively connected to the roll so that a user may obtain an unused portion of the roll by depressing the button. After shoes or feet are cleaned, they can be dried by rubbing on the drying portions of the device, which comprise a removable, moisture-absorbing material.

What is still needed in the art, however, is a modular, automated mat system that is operable for actively cleaning an entrant's shoes or the like, without tripping or otherwise being burdensome to the entrant. Preferably, such an automated mat system would be durable and self-cleaning, and could readily be installed in any conventional slab-on-grade facility.

BRIEF SUMMARY OF THE INVENTION

Accordingly, in various exemplary embodiments, the present invention provides a modular, automated mat system that is operable for actively cleaning an entrant's shoes or other object, without tripping or otherwise being burdensome to the entrant. The automated mat system is durable and self-cleaning, and may readily be installed in any conventional slab-on-grade facility. The automated mat system is customizable and multiple mat systems may be joined end-to-end to form a larger system, as desired. Each automated mat system includes alternating bands of flooring material, including replaceable heavy-duty carpet strips, brush tread strips, and vent strips. The brush tread strips are coupled to moveable rails that allow the brush tread strips to oscillate back-and-forth, thereby cleaning dirt and debris off of the entrant's shoes or other object. The vent strips include a plurality of holes that permit the dirt and debris, as well as water, to pass through into a well disposed beneath the floor, as well as permit drying air to be blown up through the floor. A floor support structure is disposed within the well, as are a drain, an actuator motor, a blower motor, appropriate electrical connections, a water source, appropriate water connections, a control system, and the like. The result is a “smart” mat system that actively cleans the entrant's shoes or other objects, as well as itself, with minimal human intervention.

In one exemplary embodiment, the present invention provides an automated mat system, including: a well structure; and a floor structure selectively disposed above the well structure, wherein the floor structure includes at least one oscillating region, at least one stationary region, and at least one vent region; wherein the at least one oscillating region is configured to clean dirt and debris from an object disposed on top of the floor structure opposite the well structure; and wherein the at least one vent region is configured to allow the dirt and debris to pass through the floor structure and into the well structure. The well structure is manufactured into a slab of a facility. The at least one oscillating region includes at least one brush tread strip, the at least one stationary region includes at least one carpet strip, and the at least one vent region includes at least one vent strip. The at least one brush tread strip, the at least one carpet strip, and the at least one vent strip are connected to one another in parallel. The automated mat system also includes an actuator motor disposed within the well structure operable for selectively oscillating the at least one oscillating regions. Optionally, the automated mat system further includes a washing assembly disposed within the well structure operable for delivering washing water through the floor structure. The automated mat system further includes a washing assembly disposed within the well structure operable for delivering washing water to the interior of the well structure. Optionally, the automated mat system further includes a dryer assembly disposed within the well structure operable for delivering drying air through the floor structure. The automated mat system still further includes a control system disposed within the well structure operable for selectively activating the automated mat system.

In another exemplary embodiment, the present invention provides a method for providing an automated mat system, including: providing a well structure; and providing a floor structure selectively disposed above the well structure, wherein the floor structure includes at least one oscillating region, at least one stationary region, and at least one vent region; wherein the at least one oscillating region is configured to clean dirt and debris from an object disposed on top of the floor structure opposite the well structure; and wherein the at least one vent region is configured to allow the dirt and debris to pass through the floor structure and into the well structure. The well structure is manufactured into a slab of a facility. The at least one oscillating region includes at least one brush tread strip, the at least one stationary region includes at least one carpet strip, and the at least one vent region includes at least one vent strip. The at least one brush tread strip, the at least one carpet strip, and the at least one vent strip are connected to one another in parallel. The method also includes providing an actuator motor disposed within the well structure operable for selectively oscillating the at least one oscillating regions. Optionally, the method further includes providing a washing assembly disposed within the well structure operable for delivering washing water through the floor structure. The method further includes providing a washing assembly disposed within the well structure operable for delivering washing water to the interior of the well structure. Optionally, the method further includes providing a dryer assembly disposed within the well structure operable for delivering drying air through the floor structure. The method still further includes providing a control system disposed within the well structure operable for selectively activating the automated mat system.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention is illustrated and described herein with reference to the various drawings, in which like reference numbers are used to denote like system components/method steps, as appropriate, and in which:

FIG. 1 is a schematic diagram illustrating one exemplary embodiment of the automated mat system of the present invention; and

FIG. 2 is a flow chart illustrating one exemplary embodiment of a method for using the automated mat system of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

Again, in various exemplary embodiments, the present invention provides a modular, automated mat system that is operable for actively cleaning an entrant's shoes or other object, without tripping or otherwise being burdensome to the entrant. The automated mat system is durable and self-cleaning, and may readily be installed in any conventional slab-on-grade facility. The automated mat system is customizable and multiple mat systems may be joined end-to-end to form a larger system, as desired. Each automated mat system includes alternating bands of flooring material, including replaceable heavy-duty carpet strips, brush tread strips, and vent strips. The brush tread strips are coupled to moveable rails that allow the brush tread strips to oscillate back-and-forth, thereby cleaning dirt and debris off of the entrant's shoes or other object. The vent strips include a plurality of holes that permit the dirt and debris, as well as water, to pass through into a well disposed beneath the floor, as well as permit drying air to be blown up through the floor. A floor support structure is disposed within the well, as are a drain, an actuator motor, a blower motor, appropriate electrical connections, a water source, appropriate water connections, a control system, and the like. The result is a “smart” mat system that actively cleans the entrant's shoes or other objects, as well as itself, with minimal human intervention.

Referring now specifically to FIG. 1, in one exemplary embodiment, the automated mat system of the present invention includes a floor structure 10 that includes multiple parts and represents a roll-up mat assembly or the like. Portions of the floor structure 10 may be made of aluminum, stainless steel, or the like. The floor structure 10 may have dimensions of 6 ft by 6 ft, or any other suitable dimensions desirable for a given application. The floor structure 10 may, optionally, be joined with other floor structures 10 using appropriate connectors or the like to form a larger floor structure. The floor structure 10 is configured to sit within or on top of a well 12 that is manufactured into the floor of a facility. The well 12 may have a depth of 6 in, or any other suitable dimension desirable for a given application. 6 in or less is often appropriate as it allows the well 12 to be accommodated in a conventional slab-on-grade facility. In one preferred exemplary embodiment, the floor structure 10 rests on a ledge or lip 14 disposed around the perimeter of the well 12. One or more support structures 16 also traverse, span, or are otherwise disposed within the well 12 and provide additional support for the floor structure 10.

The floor structure 10 includes alternating bands or regions of flooring material, including replaceable heavy-duty carpet strips or portions 18, brush tread strips or portions 20, and vent strips or portions 22. The carpet strips or portions 18 include removable areas of carpet that may be replaced when worn, for example. As such, the carpet may be secured to the underlying base using a contact adhesive, a hook-and-loop-type fastening system, pop-rivets, or the like. It will be readily apparent to those of ordinary skill in the art that other surfaces, aside from carpeting, may also be affixed to the base, or that the surface of the base may be such that it may be used alone.

The brush tread strips or portions 20 are coupled to moveable rails or areas that allow the brush tread strips or portions 20 to oscillate back-and-forth, around, etc., thereby cleaning dirt and debris off of the entrant's shoes or other object. The moveable rails or areas may be coupled to the floor structure 10, or may form a part of it. In one preferred exemplary embodiment, the brush tread strips or portions 20, in alternating fashion, oscillate back-and-forth such that the brush tread coupled to them clean dirt and debris off of the entrant's shoes or other object. Accordingly, this movement is on the scale of fractions-of-an-inch or slightly more, such that the entrant is not tripped (the stationary carpet strips or portions 18 providing the entrant with stability. Preferably, the brush tread is slightly longer and/or coarser than the carpet of the carpet strips or portions 18.

The vent strips or portions 22 include a grating or plurality of holes that permit the dirt and debris, as well as water, to pass through into the well 12 disposed beneath the floor structure 10, as well as permit washing water and/or drying air to be blown up through the floor structure 10 to the entrant's shoes or other object. This drying air may be heated. It should be noted that any number and/or configuration of vent strips or portions 22, brush tread strips or portions 20, and carpet strips or portions 18 may be utilized, with each having any suitable length, width, and thickness. The various strips may be alternated in any desired fashion.

Again, a floor support structure 16 is disposed within the well 12, and one or more other support structures may also be disposed within the well 12 to hold other components of the automated mat system 5. The automated mat system 5 includes an actuator motor 24 operable for actuating the oscillating brush tread strips or portions 20. Optionally, such actuation is accomplished using a coupled camshaft-type assembly or the like that is suitable for oscillating all of the brush tread strips or portions 20 simultaneously, although any suitable motor-driven actuation mechanism may be utilized. Appropriate electrical connections are provided to the actuator motor 24 and other electrical components. In the case that multiple floor structures 10 are used together, common well components may be used, or well components may be daisy-chained together in terms of electrical and/or fluid connections.

The automated mat system 5 further includes a blower motor 26 operable for delivering warm (or cool) drying air through the floor structure 10, as well as a water source 28 and appropriate water connections 30 operable for delivering water to the interior of the well 12 to clean it and/or through the floor structure 10. Preferably, a drain 32 is provided in the bottom of the well 12. Finally, a control system 34 is provided to control, for example, the timing of actuation of the floor structure 10, delivery of air/water through the floor structure 10, delivery of water to the interior of the well 12 to clean it, etc. Further, the automated mat system 5 may include a manual activation switch, a pressure activation switch, etc. The result is a “smart” mat system that actively cleans the entrant's shoes or other objects, as well as itself, with minimal human intervention.

Referring to FIG. 2, in one exemplary embodiment, a method for using the automated mat system 5 (FIG. 1) includes the following steps, which may be performed selectively or in a different order: (1) upon sensing pressure, that a door has opened, etc., activating the oscillation of the floor structure 10 (FIG. 1) (BLOCK 40); (2) optionally, activating the shoe spray (BLOCK 42); (3) optionally, activating the air dry (BLOCK 44); and (4) periodically activating a well cleaning cycle (BLOCK 46). Various triggers can be used to deactivate the oscillation of the floor structure, including the pressure sensor, a timer, etc.

Although the present invention is illustrated and described herein with reference to preferred embodiments and specific examples thereof, it will be readily apparent to those of ordinary skill in the art that other embodiments and examples may perform similar functions and/or achieve like results. All such equivalent embodiments and examples are within the spirit and scope of the present disclosure, are contemplated thereby, and are intended to be covered by the following claims. 

What is claimed is:
 1. An automated mat system, comprising: a well structure; and a floor structure selectively disposed above the well structure, wherein the floor structure comprises at least one oscillating region, at least one stationary region, and at least one vent region; wherein the at least one oscillating region is configured to clean dirt and debris from an object disposed on top of the floor structure opposite the well structure; and wherein the at least one vent region is configured to allow the dirt and debris to pass through the floor structure and into the well structure.
 2. The automated mat system of claim 1, wherein the well structure is manufactured into a slab of a facility.
 3. The automated mat system of claim 1, wherein the at least one oscillating region comprises at least one brush tread strip, the at least one stationary region comprises at least one carpet strip, and the at least one vent region comprises at least one vent strip.
 4. The automated mat system of claim 3, wherein the at least one brush tread strip, the at least one carpet strip, and the at least one vent strip are connected to one another in parallel.
 5. The automated mat system of claim 1, further comprising an actuator motor disposed within the well structure operable for selectively oscillating the at least one oscillating regions.
 6. The automated mat system of claim 1, further comprising a washing assembly disposed within the well structure operable for delivering washing water through the floor structure.
 7. The automated mat system of claim 1, further comprising a washing assembly disposed within the well structure operable for delivering washing water to the interior of the well structure.
 8. The automated mat system of claim 1, further comprising a dryer assembly disposed within the well structure operable for delivering drying air through the floor structure.
 9. The automated may system of claim 1, further comprising a control system disposed within the well structure operable for selectively activating the automated mat system.
 10. A method for providing an automated mat system, comprising: providing a well structure; and providing a floor structure selectively disposed above the well structure, wherein the floor structure comprises at least one oscillating region, at least one stationary region, and at least one vent region; wherein the at least one oscillating region is configured to clean dirt and debris from an object disposed on top of the floor structure opposite the well structure; and wherein the at least one vent region is configured to allow the dirt and debris to pass through the floor structure and into the well structure.
 11. The method of claim 10, wherein the well structure is manufactured into a slab of a facility.
 12. The method of claim 10, wherein the at least one oscillating region comprises at least one brush tread strip, the at least one stationary region comprises at least one carpet strip, and the at least one vent region comprises at least one vent strip.
 13. The method of claim 12, wherein the at least one brush tread strip, the at least one carpet strip, and the at least one vent strip are connected to one another in parallel.
 14. The method of claim 10, further comprising providing an actuator motor disposed within the well structure operable for selectively oscillating the at least one oscillating regions.
 15. The method of claim 10, further comprising providing a washing assembly disposed within the well structure operable for delivering washing water through the floor structure.
 16. The method of claim 10, further comprising providing a washing assembly disposed within the well structure operable for delivering washing water to the interior of the well structure.
 17. The method of claim 10, further comprising providing a dryer assembly disposed within the well structure operable for delivering drying air through the floor structure.
 18. The method of claim 10, further comprising providing a control system disposed within the well structure operable for selectively activating the automated mat system. 